Not Just For Kids: GM Uses LEGOs to Keep Track of Warranty Repairs

GM is pulling the old bucket of LEGOs out of storage, saying it's created a three-dimensional visualization system using the plastic building blocks that can help track the company's progress on pending vehicle repairs. Jointly developed with WellStar Health System, a not-for-profit health organization, the system will act as a visual to-do list, helping GM to prioritize and address potential warranty repair problems.

The process was created to improve organization and efficiency, and GM says it could reduce the time needed to implement a change by 33 percent. The visualization system will be integrated into GM's existing Problem Resolution Tracking System, which keeps track of known problems, and prioritizes them based on severity. The new system adds a visual element with LEGO blocks that represent problems. For example, if a transmission case breaks during durability testing, a block representing that problem gets placed on a board. The color of the block corresponds to where the problem is on the vehicle, while the size of the block identifies how severe the problem is. Each block is tagged with an identification number and date of discovery, and is moved along the board until the problem is resolved.

"3D Visualization allows us to look at issues more holistically," said Jamie Pickett, GM senior manager of current program quality, in a release. "By visually representing a problem it is easier to see the whole scope of it and where opportunities lie. And, unlike a line of data in a spread sheet, seeing a problem as a block on a board is a strong motivator for finding a solution to get it off the board."

In addition to tracking warranty repairs, the system will be deployed to track changes and program budgets of its vehicle engineering programs worldwide. GM says this system isn't limited to the automotive world, and that it can be applied to any process involving volume and aging. GM partner WellStar is using the system to increase efficiency in doctors' offices and generally improve patient care across its five-hospital network. If doctors are playing with LEGOs now, we suppose there's no shame in saying we still enjoy building things with the little bricks ourselves.